Multiple input welding vision system

ABSTRACT

Welding headwear comprises one or more image sensors, processing circuitry, and a display. The image sensor(s) are operable to capture an image of an unpowered weld torch as the torch passes along a joint of a workpiece to be welded. The processing circuitry is operable to: determine, through processing of pixel data of the image, one or more welding parameters as the torch passes along the joint to be welded; generate, based on the one or more welding parameters, a simulated weld bead; and superimpose on the image, in real time as the torch passes along the joint, the simulated weld bead on the joint. The display is operable to present, in real time as the torch passes along the joint, the image with the simulated bead overlaid on it.

BACKGROUND

Welding is a process that has increasingly become ubiquitous in allindustries. While such processes may be automated in certain contexts, alarge number of applications continue to exist for manual weldingoperations, the success of which relies heavily on the proper use of awelding gun or torch by a welding operator. For instance, improper torchangle, contact-tip-to-work-distance, travel speed, and aim areparameters that may dictate the quality of a weld. Even experiencedwelding operators, however, often have difficulty monitoring andmaintaining these important parameters throughout welding processes.

BRIEF SUMMARY

Methods and systems are provided for weld output control by a weldingvision system, substantially as illustrated by and/or described inconnection with at least one of the figures, as set forth morecompletely in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exemplary arc welding system in accordance with aspectsof this disclosure.

FIG. 2 shows example welding equipment in accordance with aspects ofthis disclosure.

FIG. 3 shows example welding headwear in accordance with aspects of thisdisclosure.

FIG. 4 shows example circuitry of the headwear of FIG. 3.

FIGS. 5A-5C illustrate various parameters which may be determined fromimages of a weld in progress.

FIG. 6 is a flowchart illustrating an example process for weld beadsimulation and visualization.

FIG. 7 shows a direct view of a workpiece and a mediated or augmentedreality view of a workpiece.

FIG. 8 is a flowchart illustrating an example process for assessing weldperformance using a simulated weld bead.

DETAILED DESCRIPTION

Referring to FIG. 1, there is shown an example welding system 10 inwhich an operator 18 is wearing welding headwear 20 and welding aworkpiece 24 using a torch 504 to which power or fuel is delivered byequipment 12 via a conduit 14. The equipment 12 may comprise a power orfuel source, optionally a source of an inert shield gas and, wherewire/filler material is to be provided automatically, a wire feeder. Thewelding system 10 of FIG. 1 may be configured to form a weld joint 512by any known technique, including flame welding techniques such asoxy-fuel welding and electric welding techniques such shielded metal arcwelding (i.e., stick welding), metal inert gas welding (MIG), tungsteninert gas welding (TIG), and resistance welding.

Optionally in any embodiment, the welding equipment 12 may be arcwelding equipment that provides a direct current (DC) or alternatingcurrent (AC) to a consumable or non-consumable electrode 16 (bettershown, for example, in FIG. 5C) of a torch 504. The electrode 16delivers the current to the point of welding on the workpiece 24. In thewelding system 10, the operator 18 controls the location and operationof the electrode 16 by manipulating the torch 504 and triggering thestarting and stopping of the current flow. When current is flowing, anarc 26 is developed between the electrode and the workpiece 24. Theconduit 14 and the electrode 16 thus deliver current and voltagesufficient to create the electric arc 26 between the electrode 16 andthe workpiece. The arc 26 locally melts the workpiece 24 and weldingwire or rod supplied to the weld joint 512 (the electrode 16 in the caseof a consumable electrode or a separate wire or rod in the case of anon-consumable electrode) at the point of welding between electrode 16and the workpiece 24, thereby forming a weld joint 512 when the metalcools.

As shown, and described more fully below, the equipment 12 and headwear20 may communicate via a link 25 via which the headwear 20 may controlsettings of the equipment 12 and/or the equipment 12 may provideinformation about its settings to the headwear 20. Although a wirelesslink is shown, the link may be wireless, wired, or optical.

FIG. 2 shows example welding equipment in accordance with aspects ofthis disclosure. The equipment 12 of FIG. 2 comprises an antenna 202, acommunication port 204, communication interface circuitry 206, userinterface module 208, control circuitry 210, power supply circuitry 212,wire feeder module 214, and gas supply module 216.

The antenna 202 may be any type of antenna suited for the frequencies,power levels, etc. used by the communication link 25.

The communication port 204 may comprise, for example, an Ethernet overtwisted pair port, a USB port, an HDMI port, a passive optical network(PON) port, and/or any other suitable port for interfacing with a wiredor optical cable.

The communication interface circuitry 206 is operable to interface thecontrol circuitry 210 to the antenna 202 and/or port 204 for transmitand receive operations. For transmit, the communication interface 206may receive data from the control circuitry 210 and packetize the dataand convert the data to physical layer signals in accordance withprotocols in use on the communication link 25. For receive, thecommunication interface may receive physical layer signals via theantenna 202 or port 204, recover data from the received physical layersignals (demodulate, decode, etc.), and provide the data to controlcircuitry 210.

The user interface module 208 may comprise electromechanical interfacecomponents (e.g., screen, speakers, microphone, buttons, touchscreen,etc.) and associated drive circuitry. The user interface 208 maygenerate electrical signals in response to user input (e.g., screentouches, button presses, voice commands, etc.). Driver circuitry of theuser interface module 208 may condition (e.g., amplify, digitize, etc.)the signals and them to the control circuitry 210. The user interface208 may generate audible, visual, and/or tactile output (e.g., viaspeakers, a display, and/or motors/actuators/servos/etc.) in response tosignals from the control circuitry 210.

The control circuitry 210 comprises circuitry (e.g., a microcontrollerand memory) operable to process data from the communication interface206, the user interface 208, the power supply 212, the wire feeder 214,and/or the gas supply 216; and to output data and/or control signals tothe communication interface 206, the user interface 208, the powersupply 212, the wire feeder 214, and/or the gas supply 216.

The power supply circuitry 212 comprises circuitry for generating powerto be delivered to a welding electrode via conduit 14. The power supplycircuitry 212 may comprise, for example, one or more voltage regulators,current regulators, inverters, and/or the like. The voltage and/orcurrent output by the power supply circuitry 212 may be controlled by acontrol signal from the control circuitry 210. The power supplycircuitry 212 may also comprise circuitry for reporting the presentcurrent and/or voltage to the control circuitry 210. In an exampleimplementation, the power supply circuitry 212 may comprise circuitryfor measuring the voltage and/or current on the conduit 14 (at either orboth ends of the conduit 14) such that reported voltage and/or currentis actual and not simply an expected value based on calibration.

The wire feeder module 214 is configured to deliver a consumable wireelectrode 16 to the weld joint 512. The wire feeder 214 may comprise,for example, a spool for holding the wire, an actuator for pulling wireoff the spool to deliver to the weld joint 512, and circuitry forcontrolling the rate at which the actuator delivers the wire. Theactuator may be controlled based on a control signal from the controlcircuitry 210. The wire feeder module 214 may also comprise circuitryfor reporting the present wire speed and/or amount of wire remaining tothe control circuitry 210. In an example implementation, the wire feedermodule 214 may comprise circuitry and/or mechanical components formeasuring the wire speed, such that reported speed is actual and notsimply an expected value based on calibration.

The gas supply module 216 is configured to provide shielding gas viaconduit 14 for use during the welding process. The gas supply module 216may comprise an electrically controlled valve for controlling the rateof gas flow. The valve may be controlled by a control signal fromcontrol circuitry 210 (which may be routed through the wire feeder 214or come directly from the control 210 as indicated by the dashed line).The gas supply module 216 may also comprise circuitry for reporting thepresent gas flow rate to the control circuitry 210. In an exampleimplementation, the gas supply module 216 may comprise circuitry and/ormechanical components for measuring the gas flow rate such that reportedflow rate is actual and not simply an expected value based oncalibration.

FIGS. 3 and 4 show example welding headwear in accordance with aspectsof this disclosure. The example headwear 20 is a helmet comprising ashell 306 in or to which are mounted: one or more cameras comprisingoptical components 302 and image sensor(s) 416, a display 304,electromechanical user interface components 308, an antenna 402, acommunication port 404, a communication interface 406, user interfacedriver circuitry 408, a central processing unit (CPU) 410, speakerdriver circuitry 412, graphics processing unit (GPU) 418, and displaydriver circuitry 420. The headwear also may be a functional welding maskor goggles, for example, so it can be used either for actual welding orfor simulated welding with minimal changeover.

Each set of optics 302 may comprise, for example, one or more lenses,filters, and/or other optical components for capturing electromagneticwaves in the spectrum ranging from, for example, infrared toultraviolet. In an example implementation, optics 302 a and 302 b fortwo cameras may be positioned approximately centered with the eyes of awearer of the helmet 20 to capture stereoscopic images (at any suitableframe rate ranging from still photos to video at 30 fps, 100 fps, orhigher) of the field of view that a wearer of the helmet 20 would haveif looking through a lens.

The display 304 may comprise, for example, a LCD, LED, OLED. E-ink,and/or any other suitable type of display operable to convert electricalsignals into optical signals viewable by a wearer of the helmet 20.

The electromechanical user interface components 308 may comprise, forexample, one or more touchscreen elements, speakers, microphones,physical buttons, etc. that generate electric signals in response touser input. For example, electromechanical user interface components 308may comprise capacity, inductive, or resistive touchscreen sensorsmounted on the back of the display 304 (i.e., on the outside of thehelmet 20) that enable a wearer of the helmet 20 to interact with userinterface elements displayed on the front of the display 304 (i.e., onthe inside of the helmet 20).

The antenna 402 may be any type of antenna suited for the frequencies,power levels, etc. used by the communication link 25.

The communication port 404 may comprise, for example, an Ethernet overtwisted pair port, a USB port, an HDMI port, a passive optical network(PON) port, and/or any other suitable port for interfacing with a wiredor optical cable.

The communication interface circuitry 406 is operable to interface thecontrol circuitry 410 to the antenna 202 and port 204 for transmit andreceive operations. For transmit, the communication interface 406 mayreceive data from the control circuitry 410 and packetize the data andconvert the data to physical layer signals in accordance with protocolsin use on the communication link 25. The data to be transmitted maycomprise, for example, control signals for controlling the equipment 12.For receive, the communication interface may receive physical layersignals via the antenna 202 or port 204, recover data from the receivedphysical layer signals (demodulate, decode, etc.), and provide the datato control circuitry 410. The received data may comprise, for example,indications of current settings and/or actual measured output of theequipment 12 (e.g., voltage, amperage, and/or wire speed settings and/ormeasurements).

The user interface driver circuitry 408 is operable to condition (e.g.,amplify, digitize, etc.) signals from the user interface component(s)308.

The control circuitry 410 is operable to process data from thecommunication interface 406, the user interface driver 408, and the GPU418, and to generate control and/or data signals to be output to thespeaker driver circuitry 412, the GPU 418, and the communicationinterface 406. Signals output to the communication interface 406 maycomprise, for example, signals to control settings of equipment 12. Suchsignals may be generated based on signals from the GPU 418 and/or theuser interface driver 408. Signals from the communication interface 406may comprise, for example, indications (received via link 25) of currentsettings and/or actual measured output of the equipment 12. Signals tothe GPU 418 may comprise, for example, signals to control graphicalelements of a user interface presented on display 304. Signals from theGPU 418 may comprise, for example, information determined based onanalysis of pixel data captured by images sensors 416.

The speaker driver circuitry 412 is operable to condition (e.g., convertto analog, amplify, etc.) signals from the control circuitry 410 foroutput to one or more speakers of the user interface components 308.Such signals may, for example, carry audio to alert a wearer of thehelmet 20 that a welding parameter is out of tolerance, to provide audioinstructions to the wearer of the helmet 20, etc.

The image sensor(s) 416 may comprise, for example, CMOS or CCD imagesensors operable to convert optical signals to digital pixel data andoutput the pixel data to GPU 418.

The graphics processing unit (GPU) 418 is operable to receive andprocess pixel data (e.g., of stereoscopic or two-dimensional images)from the image sensor(s) 416, to output one or more signals to thecontrol circuitry 410, and to output pixel data to the display 304.

The processing of pixel data by the GPU 418 may comprise, for example,analyzing the pixel data to determine, in real time (e.g., with latencyless than 100 ms or, more preferably, less than 20 ms), one or more ofthe following: name, size, part number, type of metal, or othercharacteristics of the workpiece 24; name, size, part number, type ofmetal, or other characteristics of the electrode 16 and/or fillermaterial; type or geometry of joint 512 to be welded; 2-D or 3-Dpositions of items (e.g., electrode, workpiece, etc.) in the capturedfield of view, one or more weld parameters (e.g., such as thosedescribed below with reference to FIG. 5) for an in-progress weld in thefield of view; measurements of one or more items in the field of view(e.g., size of a joint or workpiece being welded, size of a bead formedduring the weld, size of a weld puddle formed during the weld, and/orthe like); and/or any other information which may be gleaned from thepixel data and which may be helpful in achieving a better weld, trainingthe operator, calibrating the system 10, etc.

The information output from the GPU 418 to the control circuitry 410 maycomprise the information determined from the pixel analysis.

The pixel data output from the GPU 418 to the display 304 may provide amediated reality view for the wearer of the helmet 20. In such a view,the wearer experiences the video presented on the display 304 as if s/heis looking through a lens, but with the image enhanced and/orsupplemented by an on-screen display. The enhancements (e.g., adjustcontrast, brightness, saturation, sharpness, etc.) may enable the wearerof the helmet 20 to see things s/he could not see with simply a lens.The on-screen display may comprise text, graphics, etc. overlaid on thevideo to provide visualizations of equipment settings received from thecontrol circuit 410 and/or visualizations of information determined fromthe analysis of the pixel data.

The display driver circuitry 420 is operable to generate control signals(e.g., bias and timing signals) for the display 304 and to condition(e.g., level control synchronize, packetize, format, etc.) pixel datafrom the GPU 418 for conveyance to the display 304.

FIGS. 5A-5C illustrate various parameters which may be determined fromimages of a weld in progress. Coordinate axes are shown for reference.In FIG. 5A the Z axis points to the top of the paper, the X axis pointsto the right, and the Y axis points into the paper. In FIGS. 5B and 5C,the Z axis points to the top of the paper, the Y axis points to theright, and the X axis points into the paper.

In FIGS. 5A-5C, the equipment 12 comprises a MIG gun 504 that feeds aconsumable electrode 16 to a weld joint 512 of the workpiece 24. Duringthe welding operation, a position of the MIG gun 504 may be defined byparameters including: contact-tip-to-work distance 506 or 507, a travelangle 502, a work angle 508, a travel speed 510, and aim.

Contact-tip-to-work distance may include the vertical distance 506 froma tip of the torch 504 to the workpiece 24 as illustrated in FIG. 5A. Inother embodiments, the contact-tip-to-work distance may be the distance507 from the tip of the torch 504 to the workpiece 24 at the angle ofthe torch 504 to the workpiece 24).

The travel angle 502 is the angle of the gun 504 and/or electrode 16along the axis of travel (X axis in the example shown in FIGS. 5A-5C).

The work angle 508 is the angle of the gun 504 and/or electrode 16perpendicular to the axis of travel (Y axis in the example shown inFIGS. 5A-5C).

The travel speed is the speed at which the gun 504 and/or electrode 16moves along the joint 512 being welded.

The aim is a measure of the position of the electrode 16 with respect tothe joint 512 to be welded. Aim may be measured, for example, asdistance from the center of the joint 512 in a direction perpendicularto the direction of travel. FIG. 5C, for example, depicts an example aimmeasurement 516.

FIG. 6 is a flowchart illustrating an example process for weld beadsimulation and visualization.

In block 602, the operator 18 triggers a simulation mode. For example,the operator 18 may give a voice command to enter simulation mode whichmay be captured by the user interface of the helmet 20 and the controlcircuitry 410 may configure the components of the helmet 20 accordingly.The control circuitry 410 may also send a signal to the equipment 12 totrigger a simulation mode in the equipment 12 (e.g., to implement a lockout so that power is not actually delivered to the electrode 16 when atrigger on the gun or torch is pulled).

In block 604, an operator sets up for a weld to be simulated by placingthe workpiece, electrode, filler material, etc. in the camera field ofview. An image is captured and the pixel data of the image is analyzedto determine characteristics of the weld to be simulated. Thecharacteristics may comprise, for example: name, size, part number, typeof metal, or other characteristics of the workpiece 24; name, size, partnumber, type of metal, or other characteristics of the electrode 16and/or filler material; type or geometry of joint 512 to be welded; 3-Dposition of items (e.g., electrode, workpiece, etc.) in the capturedfield of view, and/or the like. The characteristics may be determinedby, for example, analyzing the pixel data to identify distinguishingfeatures (e.g., size, shape, color, etc.) of the workpiece, electrode,filler material, etc. and then looking those features up in a databaseto retrieve a name, part number, or the like. The characteristics may bedetermined by, for example, analyzing the pixel data to read markings(e.g., bar codes) on the items to obtain a name/part number/etc. andthen using that to retrieve additional characteristics about the itemsfrom a database.

In block 606, the operator begins a practice (“practice” is synonymousin this disclosure with “simulated”) weld. For example the operator maypull a trigger which may trigger the camera(s) to begin capturing images(e.g., at 30 frames per second or higher) and the operator may beginmoving the electrode 16 along the joint 512 as if welding, but withoutpower being delivered to the electrode 16.

In block 608, as the unpowered electrode proceeds along the joint 512,captured pixel data is processed to determine weld parameters such asthose described above with reference to FIGS. 5A-5C.

In block 610, the characteristics determined in block 604, the weldparameters determined in block 608, and equipment settings are used to arender a simulated weld bead. The equipment settings may be fixedsettings selected by the operator and/or determined automatically basedon the characteristics determined in block 604. Alternatively, theequipment settings may vary according to a model to simulate variationsin the parameters that would occur during an actual weld. In an exampleimplementation, information from other sensors may be used incombination with, or instead of, the pixel data to render the simulatedweld bead. Such sensors may include, for example, a camera mountedseparate from the helmet 20 (e.g., in or on the weld torch), anaccelerometer mounted in the helmet 20 or apart from the helmet 20, agyroscope mounted in the helmet 20 or apart from the helmet 20, and/orthe like.

In block 614, the simulated weld bead is superimposed on the capturedimages for presentation to the operator via the display 304 as part of amediated reality.

In this manner, the operator is presented with a visualization of whatthe weld would have looked like had the electrode been powered on. Thisallows the operator to practice the weld to be performed withoutdamaging the workpiece. That is, the actual workpiece may remainunaffected as shown in the left side of FIG. 7, but the mediated realityview on the display 304 displays the simulated weld bead 704 and maydisplay a simulated arc 706.

FIG. 8 is a flowchart illustrating an example process for assessingactual welding performance using a simulated weld bead.

In block 802, the operator 18 triggers a live welding mode. For example,the operator 18 may give a voice command to enter live welding modewhich may be captured by the user interface of the helmet 20 and thecontrol circuitry 410 configuring the components of the helmet 20accordingly. The control circuitry 410 may also send a signal to theequipment 12 to trigger a live mode in the equipment 12 (e.g., todisable a lock out so that power is delivered to the electrode 16 when atrigger on the gun or torch is pulled).

In block 804, an operator sets up for an actual weld to be performed byplacing the workpiece, electrode, filler material, etc. in the camerafield of view. An image is captured and the pixel data of the image isanalyzed to determine characteristics of the weld to be performed. Thecharacteristics may comprise, for example, any one or more of: name,size, part number, type of metal, or other characteristics of theworkpiece 24; name, size, part number, type of metal, or othercharacteristics of the electrode 16 and/or filler material; type orgeometry of joint 512 to be welded; 3-D position of items (e.g.,electrode, workpiece, etc.) in the captured field of view, and/or thelike. The characteristics may be determined by, for example, analyzingthe pixel data to identify distinguishing features (e.g., size, shape,color, etc.) of the workpiece, electrode, filler material, etc. and thenlooking those features up in a database to retrieve a name, part number,or the like. The characteristics may be determined by, for example,analyzing the pixel data to read markings (e.g., bar codes) on the itemsto obtain a name/part number/etc. and then using that to retrieveadditional characteristics about the items from a database. In anexample implementation, a work order associated with the weld to beperformed may be determined and then retrieved from a database. Thecharacteristics of the weld to be performed may then be extracted fromthe work order.

In block 806, equipment 12 is configured based on the determinedcharacteristics of the weld to be performed. For example, a constantcurrent or constant voltage mode may be selected, a nominal voltageand/or nominal current may be set, a voltage limit and/or current limitmay be set, and/or the like. In an example implementation, block 806 mayalso comprise configuration(s) of the camera(s). For example, expectedbrightness of the arc may be predicted (based on the equipmentconfiguration and the characteristics determined in block 804 and usedto configure the darkness of a lens filter.

In block 808, the operator begins the weld and the camera(s) begincapturing images of the weld. For example, upon the operator pulling thetrigger of the welding gun, image capture may begin and current maybegin flowing to the electrode. In an example implementation, theseevents may be sequenced such that image capture starts first and allowsa few frames for calibrating the cameras (adjusting focus, brightness,contrast, saturation, sharpness, etc.) before current begins flowing tothe electrode, this may ensure sufficient image quality even at the verybeginning of the welding operation.

In block 810, as the welding operation proceeds, captured image data isprocessed to determine, in real-time (e.g., with latency less than 100ms or, more preferably, less than 20 ms), present welding parameterssuch as those described above with reference to FIGS. 5A-5C.

In block 812, present settings and/or actual measured output of the weldequipment are determined. This may comprise receiving, for example,settings and/or measured output via the link 25. In an exampleimplementation, the circuitry 410 may adjust the settings based on theparameters determined in block 810. In this manner, equipment settingssuch as voltage, current, wire speed, and/or others may be adjusted inan attempt to compensate for deviations of the parameters from theirideal values.

In block 814, the characteristics determined in block 804, the weldparameters determined in block 810, and equipment settings and/or actualoutput determined in block 812 are used to a render a simulated weldbead. In an example implementation, a first simulated weld bead isgenerated using what the equipment settings would have been without theparameter-compensating adjustments, and a second simulated weld bead isgenerated using equipment settings as adjusted to compensate for thenon-ideal parameters.

In block 816, the simulated weld bead is superimposed on the capturedimages for presentation to the operator via the display 304 as part of amediated reality. Where more than one simulated weld bead is generated,the operator may be able to select between them via the user interface.

In live mode, the simulated weld bead(s) may, for example, be used forcalibration or verification of bead simulation algorithms and/or fordetermining the effectiveness of the real-time adjustments of the weldequipment settings.

In accordance with an example implementation of this disclosure, weldingheadwear (e.g., helmet 20) comprises one or more image sensors (e.g.,416), processing circuitry (e.g., 410 and 418), and a display (e.g.,304). The image sensor(s) are operable to capture an image of anunpowered weld torch as the torch passes along a joint of a workpiece(e.g., 24) to be welded. The processing circuitry is operable to:determine, through processing of pixel data of the image, one or morewelding parameters as the torch passes along the joint to be welded;generate, based on the one or more welding parameters, a simulated weldbead; and superimpose on the image, in real time as the torch passesalong the joint, the simulated weld bead on the joint. The display isoperable to present, in real time as the torch passes along the joint,the image with the simulated bead overlaid on it. The processingcircuitry may be operable to detect, through processing of the pixeldata of the image, distinguishing features of the joint (e.g., shape,size, local temperature, emission spectrum, etc.) and/or the workpiece(shape, size, color, markings, etc.). The processing circuitry may beoperable to retrieve characteristics of the joint and the workpiece froma database based on the distinguishing features. The characteristics maycomprise, for example, one or more of: a type of metal of the workpiece,type of welding that the torch is configured to perform, type of thejoint. The generation of the simulated weld bead may be based on thecharacteristics. The processing circuitry may be operable to determinewelding equipment settings (e.g., voltage, current, wire speed, etc.)for the joint based on determined characteristics of the joint and theworkpiece. The generation of the bead may be based on the determinedwelding equipment settings. The processing circuitry may be operable togenerate a plurality of simulated weld beads based on the determined oneor more welding parameters, wherein a first one of the plurality ofsimulated beads is based on an uncompensated version of the weldingequipment settings, and a second one of the plurality of simulated weldbeads is based on a version of the welding equipment settings that arecompensated based on the one or more welding parameters.

The simulated weld bead can be a realistic image or an enhanced imageproviding more or different information from that embodied in arealistic image. For example, if it is desirable to control thetemperature of the puddle more precisely than the operator canaccomplish by observation of a realistic or real puddle, the puddle canbe artificially colored to indicate a temperature within or outside thedesired range. This might be done, for example, by coloring the puddleyellow if it is too hot, blue if it is too cool, or green if it iswithin the preferred or required temperature range. The colors can alsobe shaded to indicate more precisely how hot or how cool the puddle iscurrently.

For example, the green color can be varied to be progressively bluer asthe temperature approaches the minimum of the green temperature rangeand progressively yellower as the temperature approaches the maximum ofthe green temperature range.

In accordance with an example implementation of this disclosure, weldingheadwear (e.g., 20) comprises one or more image sensors (e.g., 416),processing circuitry (e.g., 410 and 418), and a display (e.g., 304). Theimage sensor(s) are operable to capture an image a powered weld torch asthe torch passes along the joint 512 and creates a weld. The processingcircuitry is operable to: determine, through processing of pixel data ofthe image, one or more welding parameters for the weld; generate, basedon the determined one or more welding parameters, a simulated weld beadfor the weld; and superimpose on the image, in real time as the torchpasses along the joint 512, the simulated weld bead for the weld. Thedisplay is operable to present, in real time as the torch passes alongthe joint 512, the image with the superimposed simulated weld bead forthe weld. The simulated weld bead may be overlaid on the actual weldbead.

The present methods and systems may be realized in hardware, software,or a combination of hardware and software. The present methods and/orsystems may be realized in a centralized fashion in at least onecomputing system, or in a distributed fashion where different elementsare spread across several interconnected computing systems. Any kind ofcomputing system or other apparatus adapted for carrying out the methodsdescribed herein is suited. A typical combination of hardware andsoftware may include a general-purpose computing system with a programor other code that, when being loaded and executed, controls thecomputing system such that it carries out the methods described herein.Another typical implementation may comprise an application specificintegrated circuit or chip. Some implementations may comprise anon-transitory machine-readable (e.g., computer readable) medium (e.g.,FLASH drive, optical disk, magnetic storage disk, or the like) havingstored thereon one or more lines of code executable by a machine,thereby causing the machine to perform processes as described herein.

While the present method and/or system has been described with referenceto certain implementations, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted without departing from the scope of the present methodand/or system. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the presentdisclosure without departing from its scope. Therefore, it is intendedthat the present method and/or system not be limited to the particularimplementations disclosed, but that the present method and/or systemwill include all implementations falling within the scope of theappended claims.

As utilized herein the terms “circuits” and “circuitry” refer tophysical electronic components (i.e. hardware) and any software and/orfirmware (“code”) which may configure the hardware, be executed by thehardware, and or otherwise be associated with the hardware. As usedherein, for example, a particular processor and memory may comprise afirst “circuit” when executing a first set of one or more lines of codeand may comprise a second “circuit” when executing a second set of oneor more lines of code. As utilized herein, “and/or” means any one ormore of the items in the list joined by “and/or”. As an example, “xand/or y” means any element of the three-element set {(x), (y), (x, y)}.In other words, “x and/or y” means “one or both of x and y”. As anotherexample, “x, y, and/or z” means any element of the seven-element set{(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, “x,y and/or z” means “one or more of x, y and z”. As utilized herein, theterm “exemplary” means serving as a non-limiting example, instance, orillustration. As utilized herein, the terms “e.g. and for example” setoff lists of one or more non-limiting examples, instances, orillustrations. As utilized herein, circuitry is “operable” to perform afunction whenever the circuitry comprises the necessary hardware andcode (if any is necessary) to perform the function, regardless ofwhether performance of the function is disabled or not enabled (e.g., bya user-configurable setting, factory trim, etc.).

What is claimed is:
 1. A system comprising: welding headwear comprisingone or more image sensors, processing circuitry, and a display, wherein:said one or more image sensors are operable to capture an image of aweld torch as said torch passes along a joint of a workpiece to bewelded, said image captured as pixel data; said processing circuitry isoperable to: determine, at least in part through processing of saidpixel data, one or more welding parameters as said torch passes alongsaid joint to be welded; generate, based on said one or more weldingparameters, a simulated weld bead; and superimpose on said image, inreal time as said torch passes along said joint, said simulated weldbead on said joint; and said display is operable to present, in realtime as said torch passes along said joint, said image with saidsimulated bead.
 2. The system of claim 1, wherein said one or morewelding parameters comprise one or more of: torch work angle, torchtravel angle, torch travel speed, torch contact tip to work distance,and torch aim.
 3. The system of claim 1 wherein said processingcircuitry is operable to detect, through processing of said pixel dataof said image, distinguishing features of said joint and said workpiece.4. The system of claim 3 wherein said distinguishing features compriseone or more of: shape of said workpiece, size of said workpiece, colorof said workpiece.
 5. The system of claim 3 wherein said distinguishingfeatures comprise markings on said workpiece.
 6. The system of claim 3,wherein: said processing circuitry is operable to retrievecharacteristics of said joint and said workpiece from a database basedon said distinguishing features; and said database storescharacteristics for a plurality of joints and workpieces.
 7. The systemof claim 6, wherein said characteristics comprise one or more of: a typeof metal of said workpiece, type of welding that said torch isconfigured to perform, type of said joint.
 8. The system of claim 7,wherein said generation of said simulated weld bead is also based onsaid characteristics.
 9. The system of claim 3, wherein said processingcircuitry is operable to determine a work order associated with saidweld piece is based on said distinguishing features.
 10. The system ofclaim 9, wherein said processing circuitry is operable to: retrieve saidwork order from a database; and extract characteristics of said jointand said workpiece from said work order.
 11. The system of claim 10,wherein said characteristics comprise one or more of: a type of metal ofsaid workpiece, type of welding that said torch is configured toperform, and type of said joint.
 12. The system of claim 11, whereinsaid generation of said bead is also based on said characteristics. 13.The system of claim 1, wherein said processing circuitry is operable to:determine, through processing of said pixel data of said image,characteristics of said joint and said workpiece; and determine weldingequipment settings for said joint based on said characteristics of saidjoint and said workpiece.
 14. The system of claim 13, wherein saidwelding equipment settings comprise one or more of: amps, volts, wirespeed, and gas flow rate.
 15. The system of claim 13, wherein saidgeneration of said bead is based on determined welding equipmentsettings.
 16. The system of claim 15, wherein: said processing circuitryis operable to generate a plurality of simulated weld beads based onsaid determined one or more welding parameters; a first one of saidplurality of simulated beads is based on an uncompensated version ofsaid welding equipment settings; and a second one of said plurality ofsimulated weld beads is based on a version of said welding equipmentsettings that are compensated based on said one or more weldingparameters.
 17. The system of claim 1, wherein: said one or more imagesensors are operable to capture a second image of a powered weld torchas said torch passes along said joint and creates a weld; saidprocessing circuitry is operable to: determine, through processing ofpixel data of said second image, one or more second welding parameters;generate, based on said determined one or more second weldingparameters, a simulated weld bead for said weld; and superimpose on saidsecond image, in real time as said torch passes along said joint, saidsimulated weld bead for said weld; and said display is operable topresent, in real time as said torch passes along said joint, said secondimage with said superimposed simulated weld bead for said weld.
 18. Thesystem of claim 17, wherein said generation of said bead is based onweld equipment settings received from welding equipment by saidprocessing circuitry in real time as said torch passes along said jointto create said weld.
 19. The system of claim 1, wherein said weldingheadwear is a helmet.
 20. The system of claim 1, wherein: said weldingheadwear comprises a microphone; and said processing circuitry isoperable to adjust said display in response to voice commands receivedvia said microphone.